MX2007010678A

MX2007010678A - Two piece surface mount header assembly having a planar alignment surface.

Info

Publication number: MX2007010678A
Application number: MX2007010678A
Authority: MX
Inventors: Daniel Williams Fry Jr; John Mark Myer; Hurley Chester Moll
Original assignee: Tyco Electronics Corp
Priority date: 2005-03-01
Filing date: 2006-02-24
Publication date: 2007-11-12
Also published as: CN101171724B; EP1854181B1; US7086872B2; BRPI0607397A2; JP2008532247A; JP4678696B2; TW200640096A; CN101171724A; EP1854181A1; WO2006093921A1; US20050148219A1; TWI346427B; CA2601308A1; CA2601308C; KR20070106020A

Abstract

A header assembly (300) includes an insulative contact housing (302) having a plurality of walls defining an interior cavity and an insulative alignment housing (304) having at least one alignment rib (370) extending on an exterior surface thereof. The alignment housing (304) is separately provided and independently mounted to the contact housing (302). A plurality of contacts (306) are included within the cavity and extend through one of the walls to an exterior of the contact housing (302) wherein the contacts (306) flex against the alignment housing (304) and abut the alignment rib (370), thereby ensuring coplanarity of the contacts for surface mounting to a circuit board.

Description

ASSEMBLY OF TRANSVERSE CHANNEL OF SURFACE MOUNTING OF TWO PIECES THAT HAS A SURFACE FLAT ALIGNMENT Presented by Solicilud is a statement in part of the US Patent Application Serial No. 10 / 718,371 filed November 20, 2003, which is incorporated in its entirety to the present invention as a reference. Field of the Invention The present invention relates generally to electrical connectors, and more specifically, to transverse channel assemblies, for coupling engagement with socket assemblies. BACKGROUND OF THE INVENTION Coupling a plug assembly into a receptacle assembly to form a connector assembly often involves a higher insertion force. This is particularly true when the connector comprises coupling housings for the connector which contain many contacts. For example, automotive wiring systems, such as power-line systems, usually include electrical connectors. Normally each electrical connector includes a plug assembly and a cross channel assembly. The assembly of The plug is engaged in an assembly of the transverse channel assembly. The transverse channel assembly in turn is mounted on a circuit board along a concave interface. At least some known receptacle assemblies are rectangular angle receptacle assemblies wherein the plug assembly is coupled in a direction that is parallel to the contact interface between the transverse channel assembly and the circuit board. Each of the plug assemblies and the transverse channel assembly normally includes a large number of electrical contacts, and the contacts in the transverse channel assembly are electrically and mechanically connected to respective contacts in the plug assembly, when the channel assembly cross section and plug assembly are engaged. To overcome the superior insertion force for connecting the plug assembly to the transverse channel assembly, an action lever is sometimes employed to couple the contactors of the plug assembly with the transverse channel assembly. The cross-channel mounting assemblies on the surface provide a number of venlages, with respect to the cross channel assemblies mounted in holes. In addition to offering advantages in terms of cost and process, surface mounting allows a reduced pressure area for the transverse channel assembly, and therefore saves a valuable space in a labyrinth of circuits or allow a reduction in the size of the labyrinth of circuits. When the transverse channel assembly is mounted on the surface to a circuit board, the weld extends from one side of the transverse channel assembly in an angled form for surface mounting to a circuit board, and also extends in shape substantially perpendicular from another side of the transverse channel assembly for the coupling engagement with the contacts of the socket assembly. In an automotive connector system, two links are used in one version of the transverse channel assembly, and the large number of connections presents manufacturing and assembly challenges in the fabrication of the transverse channel assembly, as well as installation problems during assembly on the surface of the transverse channel assembly. For example, it is desirable for surface mounting that the weld of the cross channel assembly be co-planar to another to be mounted to the plane of a circuit board. Achieving coplanarity with the large number of contact bolts, however, is difficult due to manufacturing tolerances with respect to a large number of contacts. Sometimes an additional solder paste is used to compensate the tolerances of the counters or the misalignment of the pin contacts during the channel assembly.

Transversal However, in a large number of transverse channel assemblies, the sewing in increment of the increased amount of solder paste per transverse channel assembly can be significant, and the non-planarity of the bolt counters with respect to the plane of the transom board. circuits, can negatively affect the reliability of the transverse channel assembly. The additional thickness of the welding pass can also cause problems with the welding pricking of other surface mounting components at a fine feed or may require different stencils to be used. Depending on the degree of non-planarity of the welds, some of the links may be weakly connected or not be connected at all to the circuit board, any of which is an undesirable and unacceptable result. In addition, the upper insertion forces during the engagement and disengagement of the transverse channel assembly and the plug assembly can be detrimental to the welded connections of the transverse channel assembly. To avoid broken weld connections, sometimes a welding fastener is used which is welded to the circuit board at the corners of the head. In this way, the mechanical connection of the welding fasteners incurs the onset of the mechanical deformation according to the channel assembly The transverse is coupled and uncoupled from a coupling connector. The tolerances in the manufacture of the welding fasteners, however, introduce additional aspects of non-planarity when the transverse channel assembly is welded to a circular laminar. At one end of the tolerance range, the welding fasteners can prevent the contacts from making a total contact with the circuitry, which can damage the quality of the soldered connections of the contacts. In the extreme case of the range of tolerance, the welding fasteners may not necessarily conjoin the circuits labyrinth during welding, which damages the ability of the welding fasteners to hold the contacts of higher insertion and extraction forces, according to the assembly. of transverse channel is being coupled and decoupled in a coupling connector. The solution to the problem is the non-coplanarity of the conlactos in a transversal channel assembly mounted on a surface. BRIEF DESCRIPTION OF THE INVENTION The solution to the problem is provided through a connector assembly comprising an insulating contact housing having a plurality of walls defining an interior quality and an insulating alignment housing that has at least one alignment rib that is extendable in an exior surface of the same. The accommodation of Alignment is provided separately and mounted independently of the contact housing. A priority of contacts is included within the cavity and extend through one of the walls to an exterior of the contact housing where the cores flex against the aligning housing and rest against the alignment rib, securing the same. forms the coplanarity of the connectors for mounting on the circuit board. BRIEF DESCRIPTION OF THE DRAWINGS The present invention will now be described by way of example with reference to the accompanying drawings, in which: Figure 1 is a top perspective view of a housing for a transverse mounting channel assembly in a formed surface as described in an exemplary embodiment of the present invention. Figure 2 is a perspective view from the bottom of the mosdyred housing in Figure 1. Figure 3 is a front elevational visia of a first conical assembly made with the housing shown in Figures 1 and 2. Figure 4 is a view in lateral elevation of the contacts shown in Figure 3. Figure 5 is a front elevation view of a second assembly of contacts used with a housing shown in Figures 1 and 2. Figure 6 is a side elevational view of the contacs shown in Figure 5. Figure 7 is a top view of a weld fastener formed as described in an embodiment of the present invention. Figure 8 is a cross-sectional view of a transverse channel assembly formed therein as described in the present invention in a first stage of manufacture. Figure 9 is a partial cross-sectional view of the assembly of the transverse channel shown in Figure 8 along line 9-9 of Figure 2. Figure 10 is a partial cross-sectional view of the channel assembly. cross section shown in Figure 8, along line 10-10 of Figure 2. Figure 11 is a cross sectional view of the cross channel assembly in a second manufacturing step. Figure 12 is a cross-sectional view of the assembly of the transverse channel in a third stage of manufacture. Figure 13 is a cross-sectional view of the assembly of the transverse channel in a final stage of manufacture. Figure 14 is a perspective view from the bottom of the transverse channel assembly shown in Figure 13. Figure 15 is a perspective view of a transverse channel assembly assembled on an alternating surface, formed as described in an allernalizing embodiment of the present invention. Figure 16 is a perspective view from the bottom of a contact housing for the transverse channel assembly shown in Figure 15. Figure 17 is a perspective view from the bottom of an alignment housing of the channel assembly. FIG. 18 is a front elevational view of a first contactor assembly used when the transverse channel assembly shown in FIG. 15. FIG. 19 is a front elevation view of a transverse channel shown in FIG. second contact assembly used with the transverse channel assembly shown in Figure 15. Figure 20 is a side elevational view of the contact housing and contact assemblies formed as described in an alternative embodiment of the present invention in a first stage of manufacture. Figure 21 is a perspective view from the bottom of the cross channel assembly shown in Figure 15 in a second manufacturing step. Figure 22 is a perspective view from the bottom of the transverse channel assembly shown in Figure 15 in a final fabrication step. Detailed Description of the Invention FIGS. 1 and 2 are views in upper and lower perspective, respectively, of an example housing 100, sometimes referred to as a mantle, for a transverse mounting assembly on a surface formed as described in FIG. an exemplary embodiment of the present invention. The housing 100 includes a pair of longitudinal end walls 102, a pair of side walls 104 that extend between the ends of the longitudinal side walls 102, and a bottom wall 106 that extends between the side longitudinal and side walls 102 and 104 The side walls 102 and 104 and the bottom wall 106 collectively define a contact cavity 108 in the upper part of the housing 100 (FIG. 1), and a counter interface 110 in the bottom of the housing 100 (FIG. 2). A first contact opening row or row 112 and a second row or inner row of contact opening 114 are provided across the bottom wall 106 in a parallel relationship to each of the long-term laminar walls 102 of the housing. 100, providing in this manner any opening rows extending from the contact cavity 108 through the bottom wall 106 towards the contact interface 110. In the illustrated mode, each of the rows of contact openings 112 and 114 includes thirteen counted openings, thereby providing a housing of fifty-two positions (13 x 4) 100. However, it is recognized that more or less can be provided openings in more or less rows in several alternative modalities without departing from the spirit and scope of the present invention. Lever slots 116 are formed in each of the longitudinal side walls 102 in communication with the contact cavity 108 (Fig. 1). The lever slots 116 are configured to receive and hold the actuating lever of a coupling connector (not shown) to fit the electrical contacts of the coupling connector with the electrical contacts (described later) found in the channel cross. Various slots and keys 118 are provided on the longitudinal side walls 102, the side walls 104, and the bottom wall 106 of the housing 100 for guiding the coupling portions of the coupling connector to align the electrical contacts of the transverse channel and the coupling coneclor. However, it will be understood that in alternative embodiments, the lever slots 116 and / or the slots and keyed presentations 118 may be omitted in a hand-assembled (for example, non-assylated) connector.

The mounting seats of the welding fastener 120 extend outwardly from the outer surfaces 122 of each of the side walls 104 between the longitudinal side walls 102. The alignment seats 124 also extend outwards from each of the outer surfaces. 122 of the side walls 104 at the corners of the housing 100. Each of the alignment seats 124 includes an inclination rib 126 (Figure 1) on an end surface 127 thereof. As will be explained further, the moniage legs 120, the alignment pins 124 and the inclination ribs 126 serve to locate the welding fasteners (described further below) in each of the laminar walls 104 of the housing 100, so that the surfaces of the welding fasteners are placed coplanarly with the welds at the contact interface 110 (Fig. 2) of the housing 100. Holes or slots 121 can be provided around the assembly seats 124 for collection and cut or thin shaved parts of the seats 120 as welding fasteners are installed. Notches 129 are provided at the bottom end of the side walls 104, and the notches are used to retain the welding fasteners to the side walls 104, as will be explained later. Optionally, and in an example mode, the seats 128 extend outward from the longitudinal side walls 102 at the corners of the housing 100. The seats 128 provide a key feature for a coupling connector on an exterior surface 130 of the longitudinal side walls 102. Although the seats 124 and 128 are illustrated with a substantially rectangular shape, it is recognized that other forms of the seats 124 and 128 may be used in an alternative manner in other embodiments of the present invention. With reference to figure 2, the contact interface 110 of the housing 100 includes a slotted positioning member 132 extending parallel to the longitudinal side walls 102, and a slot is provided in the positioning element 132 of each contact opening in the outer row of the openings 112 and the inner row of the openings 114. When receiving the welds of the contacts (described later) in the respective slots of the positioning member 132, the welds are prevented from moving in the direction of the arrow A, which is extends substantially parallel to a longitudinal axis 133 of the housing 100. The contact interface 110 further includes an alignment surface 134 extending in an alignment rib 136 adjacent each of the longitudinal side walls 102. The alignment surfaces 134 are coplanas enlre yes and eslan separated laterally of the positioning elements 132 so that the positioning elements 132 are located between the alignment surfaces and the respective outer row of the contact apertures 112. As will be explained later, the alignment surfaces 134 provide a surface of registration which ensures that the ends of the welds at the contact interface 110 are coplanar to each other. The pre-loading of the welds against the alignment surfaces 134, as will be explained below, prevents the welds from moving in the direction of the arrow B which extends perpendicular to the longitudinal axis 133. In an exemplary embodiment , the positioning element 132, the alignment rib 136 and the alignment seats 124 are formed integrally with each other. By forming the alignment rib 136 and the alignment seats 124 in an integral mode, the upper surface 127 (FIG. 1) of the alignment seats 124 is located at a fixed distance from the alignment surfaces 134. Therefore, the Welding fasteners can be positioned accurately with respect to the alignment surface, as described below, to achieve the coplanarity of the welding fasteners with the alignment surfaces 134. As alternating, the alignment rib 136, the positioning element 132, and alignment seats 124 can be manufactured separately and adhered to housing 100.

In an exemplary embodiment, the housing 100, including each of the above-mentioned structural features, is formed integrally from an electrically insulative (ie, non-conductive) material, such as plastic, as described in a known process. , such as an injection molding process. However, it is recognized that the housing 100 may alternatively be formed of separate pieces or other materials that may be recognized in the art. Figure 3 is a front elevation view of a first counting group 150, which can be used in the outer row of the counting apertures 112 (shown in Figures 1 and 2) of the housing 100. In an example embodiment, the counted group 150 includes countertop sections 152, perforation sections 154 and welding sections 156. The aperture sections 154 are dimensioned to produce an interference fit when inserted into an aperture found in the row of contact apertures. 112, and the counted sections 152 and weld sections 156 are aligned along each other along a common cross line 157. Cross-sectional cross-sectional layers 158 join the perforation sections 154, when the transfer lugs 158 are sheared during assembly. of the transverse channel, the group of links 150 is separated into individual contacts.

Although only two contacts are shown in Figure 3, it will be understood that contact group 150 includes a number of contacts corresponding to the number of contact openings in contact rows 112 (shown in Figures 1 and 2). The group of contacts 150 can be manufactured from a single piece of metal, such as copper or a copper alloy, and in addition can be coated or coated with tin, lead, gold, etc., as necessary to obtain the mechanical characteristics and desired electrical and contact group properties 150. FIG. 4 is a side elevation view of counting group 150 illustrating a small radius formed at one end 160 of welding sections 156. The radius creates a rounded end 160 which, as will be appreciated below, mitigates the tolerances or misalignment of the conaction group 150, as the transverse channel is assembled. In an allernaliva modality, the radius can be omilido and the exír of the group of contacts 150 can be straight. Figure 5 is a front elevation view of a second group of contacts 170 which can be used in the inner row of the contact apertures 114 (shown in Figures 1 and 2) of the housing 100. In an exemplary embodiment , the counted group 170 includes counted sections 172, opening sections 174 and welding sections 176. Opening sections 174 are formed and dimensioned to produce an inference fit when an aperture is inserted in the row of the contact apertures 114 and the contact sections 172 in the welding sections 176 are offset relative to one another relative to the aperture sections 174. That is, the count sections 172 and the welding sections 176 have spaced-apart centimeter lines. The compensation in the sealing sections 172 and the welding sections 176 achieves a desired centerline spacing of the welding sections 176 relative to the welding sections 156 (shown in FIGS. 3 and 4) when the connecting groups 150 and 170 are installed in the housing 100. Because the contact group 170 is installed to the inner row of the contact apertures 114, the contact group 170 has a length L greater than the first group of contacts 150 which it is installed in the outer row of the counted openings 112 in the housing 100. The transverse transfer lugs 178 join the opening sections 174, and when the transfer lias 178 are sheared during the assembly of the transverse channel, the group of links 170 is separate into individual contacts. Although only two contacts are shown in FIG. 5, it will be understood that the group of contactors 170 includes a number of corresponding records, to the number of contacts that exist in the counted rows 114. contacts 170 can be manufactured from a single piece of metal, such as copper or a copper alloy, and can also be coated or coated with tin, lead, gold, etc. as necessary to have the desired electrical and mechanical characteristics and properties of the contact group 170. Figure 6 is a side elevation view of the group of contacts 170 illustrating a small radius formed at one end 180 of the welding sections 176. The radius creates a rounded end 180, which as will be appreciated below, mitigates the tolerances or misalignments of the counted group 170 as the transverse channel is assembled. In an alternate embodiment, the radius may be omitted and the ends of the counted group 170 may be straight. Figure 7 is a top plan view of a welding fastener 190 formed therein as described in an exemplary embodiment of the present invention. The fastener 190 includes a main body section 192 having mounting apertures 194 and alignment apertures 196. The mounting apertures 194 are formed and sized for insertion through pressure into the mounting seats 120 of the housing 100 (shown in FIG. Figs. 1 and 2), and the alignment openings 196, are designed and sized to receive the alignment seats 124 (shown in Figs. 1 and 2) of the housing 100. Therefore, the fastener The weld 190 may be aligned vertically in the direction of the arrow C and horizontally in the direction of the arrow D when the welding fasteners 190 are installed in the respective side walls 104 of the housing 100. A belt loop is formed. retention 198 at one end 191 of the body section 192 that faces toward the contact interface 110 (shown in Figure 2) of the housing 100, when the welding fastener 190 is installed. The clip 198 can be bent into a wall side 104 and retained in notch 127 (shown in figure 2) that is there. The edges 202 of the alignment openings 196 contact the inclination ribs 126 (shown in FIG. 1) of the alignment seats 124 of the housing 100. Accordingly, a safety against movement of the welding fastener 190 is provided. length of two mutually perpendicular axes indicated by the arrows C and D. In an exemplary embodiment, the welding fastener 190 is made of a sheet of metal as described in a stamping and forming operation. However, it is recognized that the welding fastener 190 can be manufactured from a variety of materials as described in various processes known in the art, in alternative embodiments.

Although in an example embodiment the retaining clip 198 is given the form of a T, it will be understood that various shapes can be used in place of a T-shape in alternate embodiments, to replenish the welding fastener 190 to a side wall 104 of the housing 100. The alignment clips 204 project from the edge 191 and include surfaces of lace on the welding bracket board 206, which are flat and smooth. The fitting surfaces on the board 206, make conical with the flat surface of a circuit board during the surface assembly of the transverse channel assembly and are welded to the circuit board. The welding of the alignment clips 204 provides a structural strength and stiffness, which provides the release of deformation to the welded connections of the groups of links 150 and 170. Figure 8 is a cross-sectional view of a transverse channel assembly. 200 in a first stage of manufacture. The cross channel assembly 200 includes the housing 100 with contact groups 150 and 170 inserted in the outer and inner rows of the countertop openings 112 and 114 (shown in Figures 1 and 2). The counted sections 152 and 172 of the respective condensation groups 150 and 170 are partially located in the contact cavity 108 while the welding sections extend from the contact interface 110 and the housing 100. FIG. 9 is a partial cross sectional view of transverse channel assembly 200 through the end row of the contact apertures 112. The aperture sections 154 of the contact group 150 extend partially into the contact openings of row 112 at a predetermined distance, and the sections opening 154 of the counting group 150 extend partially from the counting interface 110 and the housing 100. The transporting belts 158 (shown in figure 3) have been sheared from the contact group 150, thereby forming independent counting in the openings that are in the row of openings 112. The welding sections 156 of the clearing group 150 are located between the welding sections 176 of the contact group 170, and the centerlines of the welding sections 176 and 156 are separated in a way that consists of yes. Figure 10 is a transverse sectional view of the transverse channel assembly 200 through the inner row of the contact apertures 114. The aperture sections 174 of the contact group 170 extend partially into the row conical apertures. 114 for a previously demineralized gap, and the perforation sections 174 of the connecting group 170 are partially expelled from the contact interface 110 of the housing 100. The conveyer strips 178 (shown in FIG. 5) have been Unscrambled from the contact group 170, thus forming independent contacts, in the openings in the contact opening row 114. The welding sections 176 of the contact group 170 are located between the welding sections 156 of the group 150 150, and the cross-sections of the welding sections 176 and 156 are separated in a consis- tent manner from one another. Figure 11 is a cross-sectional view of the transverse channel assembly 200 in a second fabrication stage where the tooling, such as forming dies 210 and 212, is employed to flex weld sections 156 and 176 toward the interface 100 of the housing 100. Once the forming ion 212 is removed, those counted can be additionally inserted through the contact inlet 110 by seating the forming die 210 in the direction of the E arrow for bring the bent welding sections 156 and 176 towards the counting interface 110. Although the described embodiment thus includes the bending of the clearing groups 150, 170 after they have been partially insulated in the housing 100, it is recognized that the counters 150, 170 may be flexed prior to installation to housing 100 in an alimentary mode. Figure 12 is a cross-sectional view of the transverse channel assembly 200 in a manufacturing process section, wherein the piercing sections 154 and 174 (shown in FIGS. 9 and 10) are completely inserted into the respective rows of contact openings 112 and 114 in the housing 100 to a final position. In the final position, the welding sections 156 and 176 are adapted through the slots in the positioning element 132 (also shown in Figure 2), and the rounded ends 160 and 180 of the respective welding sections 156 and 176 they are aligned with each other and in the support gap in the alignment rib 136. As shown in FIG. 12, the alignment surface 134 is rounded or crowned and formed to gently establish contact with the rounded end 160 and 180 of the ends. counted groups 150 and 170. The welding sections 156 and 176 are bent from the position shown in FIG. 11 and are oriented obliquely towards the contact interface 110 of the housing 100, thereby creating an internal tilt force in FIG. the contact groups 150 and 170 which previously load the welding sections 156 and 176 against the alignment surfaces 134 of the alignment ribs 136. D The inclination or preload of the welding sections 156 and 176, substantially avoids the vertical movement of the welding sections 156 and 176 in the direction of the arrow B according to the channel assembly.

Transverse 200 is handled before the surface assembly during the installation of the surface mount. In addition, a final angle a of the welds 156 and 176 with respect to an upper surface 230 of the side walls 104, ensures a satisfactory weld joint to a circuit board. The annular alignment surfaces 134 of the alignment ribs 136 and the rounded ends 160 and 180 of the welding sections 156 and 176 allow some misalignment of the welding sections 156 and 176, as the contact groups 150 are installed. and 170. The rounded fit surfaces of the alignment surfaces 134 and the ends 160 and 180 of the contact groups 150 and 170 allow the displacement of the contact points between the fitting surfaces, as the contact groups move 150. and 170 towards the final position. Since the welding sections 156 and 176 are preloaded against the alignment ribs 136, the relative misalignment of the welds is substantially, if not completely, eliminated and the rounded edges 160 and 180 of the contact groups 150 and 170 are substantially aligned to produce points, tangential coplanar contact points with rounded ends for mounting to a circuit board. Although in the illustrated embodiment the alignment surfaces 134 are in the crown and the ends 160 and 180 of the contact groups 150 and 170 are rounded, it will be appreciated that in an alternative embodiment the alignment surface may be substantially flat and the contact ends may be substantially straight, notwithstanding the alignment of the counted ones in a flat relationship with each other for Surface mounting to a circuit board. Figure 13 is a cross-sectional view of a cross channel assembly 200 in a final manufacturing step, when the welding fasteners 190 are adhered to the housing 100. The engagement surfaces 206 of the alignment clips of the welding fastener 204 they are coplanar with the counted ends 160, 180 of the groups of contacts 150 and 170. The interface of the contactor 110, therefore, is well adapted for surface mounting to a flat surface 220 of a circuit board 222. FIG. 14, is a perspective view of the bottom of the assembly of the transverse channel 200 when it is completely assembled. The welding fasteners 190 are coupled to the laminar walls 104 of the housing 100 and are retained thereto through retaining clips 198. The welding sections 156 and 176 are preloaded and supported against the alignment surfaces 134 adjacent to the walls. longiludinal latents of the housing 100. The manufacturing tolerances in the manufacture of contact groups 150 and 170, are mitigated and the welding sections 156 and 176 are subsanially aligned and coplanar for the moniage to the flat surface 220 of the laminar 222 (shown in Figure 13). The alignment surfaces of the board of the welding fasteners 206 are substantially aligned and coplanar with the welding sections 156 and 176 for secure mounting to the circuit board 222 in the plane of the welding sections 156 and 176. Accordingly, they can use relatively thin and consistent solder paste films, to reliably weld the cross channel assembly 200 to the circuit board 222. For all of the above reasons, a safe and reliable cross-channel assembly is provided for assembly applications in surface, which resistively capable higher forces of insertion and removal when the transverse channel 200 is engaged and disengaged from a coupling connector. Figure 15 is a top perspective view of an alternative surface mounting transverse channel assembly 300 formed as described in an alternative embodiment of the present invention. In the illustrated embodiment, the transverse channel assembly 300 is a right angle surface mount cross channel assembly and may be oriented along an engaging surface 301 of a circuit board 303 (shown in ghosts in the figure). fifteen). The cross channel assembly 300 includes a housing of conlaclos or mantle 302, an alignment housing 304 adhered to housing 302, and a plurality of contacts 306 housed within and / or aligned through contact housing 302 and alignment housing 304, as will be explained in more detail ahead. The contactor housing 302 and the alignment housing 304 are separately fabricated and separate elements mounted one on the other to orient the connectors 306 with respect to the circuitry 302. In an exemplary embodiment, the connector housing 302 is a previously manufactured and known contact housing and the alignment housing 304 is manufactured to be retro-adjusted to adhere to the socket housing 302 and to align the connectors as described below. The contact housing 302 and the alignment housing 304 may each be individually or collectively coupled to the circuit board 303, so that the counters 306 mesh with the engaging surface 301 in a substantially flat orientation. In an exemplary embodiment, the alignment housing 304 is coupled to the conferencing housing 302. The alignment housing 304 includes mounting features on the frame 308 to mount the transverse channel assembly 300 to the circuit board 303. In alternating modes, the alignment housing 304 includes fastening frames of the fastener of welding (not shown), and the cross channel assembly 300 is mounted to the circuit board 303 through welding fasteners (not shown). As alternating, the contact housing 302 may include board mounting features (not shown) for mounting the cross channel assembly 300 to the circuit board 303. FIG. 16 is a perspective view of the bottom of the contact housing 302. The contact housing 302 includes a pair of longitudinal side walls 312, a pair of side walls 314 extending between the ends of the side longitudinal walls 312, and a contact interface 316 extending between the longitudinal and side walls 312 and 314. The side walls 312 and 314 and the contact interface 316 collectively define a concave cavity 318 of the housing 302. An interface of plugs 320 extends between the longitudinal and side walls 312 and 314 and is generally opposite to the other. the contact interface 316. The interface of the plug 320 is oriented to receive a plug assembly (not shown) and incl. uye an opening (not shown in figure 16) that extends allowing access to the contact cavity 318. In the illustrated embodiment, one of the longitudinal side walls 312 is oriented to fit the engaging surface 301 (shown in FIG. figure 15) when the transverse channel assembly 300 is coupled to the circular laminar 303 (shown in figure 15). A cavity axis 321 extends between and is substantially perpendicular to each of the contact interfaces 316 and the interface of the plug 320. In contrast to the housing 100, the axis of the cavity 321 of the housing 302 is oriented in substantially parallel fashion to the fitting surface 301 of the circuit board 303. A first row or upper row of countertop openings 322 and a second row or lower row of contact openings (not shown in FIGS. 16) are provided through the interface of contact 316 in a relationship parallel to each of the longitudinal side walls 312 of the contact housing 302. The lower row of contact openings extends substantially parallel to and separates from the upper row of the contact openings 322. In one example mode, each of the rows of contact openings includes thirteen contact openings. However, it is recognized that more or fewer openings may be provided in more or fewer rows in various alternating modes, without departing from the spirit and scope of the present invention. Alignment seats 330 extend outward from the outer surfaces 332 of each of the sidewalls 314 between the longiludinal sidewalls 312. The alignment seats 330 are positioned proximate the contact surface 316 of the contact housing 302.

Each of the alignment pins 330 serves to locate the alignment housing 304 (shown in Figure 15) in relation to the accommodation of links 304 and provide a keying feature for the alignment housing coupling 304 to the contact housing 302 along one of the longitudinal side walls 312. Although the alignment seats 330 are illustrated as having a substantially rectangular shape, it is recognized that other forms of the seats 330 can be used alternatively in other embodiments of the present invention. providing a latch or retention fastener 336 on an exterior surface 338 of the alignment seats 330. The latches 336 serve to retain the alignment housing 304, as will be explained later, when the transverse channel assembly 300 is assembled. an example mode, the hosting of contacios 302, including each one of the c The aforementioned structural features are formed in an organic manner from an electrically insular (ie, non-conductive) material as a plastic, as described in a known process, as an injection molding process. However, it will be recognized that the housing can alternatively be formed from separate pieces and other materials as are known in the art.

Figure 17 is a perspective view of the bottom of the alignment housing 304. The alignment housing 304 includes a pair of laterally spaced side walls 340. The side walls include an upper edge 342, a lower edge 344, an internal side edge 346 and an outer side edge 348. In the illustrated embodiment, the top edge of each wall 340 is grooved between the inner and outer side edges 346 and 348. A longitudinal wall 350 extends between the top edges 342 of the side walls 340. An alignment member 352 extends between the side walls 340 and is positioned proximate the outer side edge 348 of each side wall 340. The side walls 340, the longitudinal wall 350, and the alignment member 352 collectively define a cavity of alignment 354 within housing 304. As will be explained later in detail, contacts 306 (shown in Figure 15) are aligned within the alignment cavity 354 for engagement on the surface with the circuit board 303 (shown in Figure 15). The alignment housing 304 also includes an assembly of the contact housing 356 extending from the inner side edge 346 of each of the side walls 340. The housing assembly 356 includes an opening that extends between the inner side edges 346 of the side walls 340 to allow access from the contact housing 302 (shown in Figure 16) to the alignment pocket 354. Specifically, when the cross channel assembly 300 is assembled, the contact interface 316 (shown in Figure 16) of the contact housing 302 is oriented within the aperture, thereby allowing the contact 306 to extend into the alignment cavity 348. The housing assembly 356 also includes a pair of mounting cavities 358 extending outwardly from the aperture. The mounting cavities 358 are designed and shaped to fit the alignment seats 330 (shown in FIG. 16) that extend from the side walls 314 (shown in FIG. 16) of the contact housing 302. The housing assembly 356 includes retaining clips 360 positioned proximal to each mounting cavity 358. Retaining clips 360 include notches or grooves 362 thereon to engage the locks 336 (shown in Fig. 16) extending from the alignment seats 330. Accordingly, the retaining clips 360 ensure that the alignment housing 304 to the socket 302. In addition, the retention clip 360 can be moved from it. so that the locks 336 can be released, and the transverse channel assembly 300 can be disassembled. Specifically, a force can be applied to retention clips 360 in one direction generally outwardly to the mounting cavities 358 until the latches 336 are no longer retained within the slots 362, and the alignment housing 304 can be disengaged from the contact housing 302. The alignment member 352 is separated from the housing. perforation extending between the inner side edges 346 of the side walls 340. The alignment member 352 includes a slotted positioning element 364 extending substantially parallel to the opening, and a slot is provided in the positioning element 364 for each spot opening at the contact interface 316. As described below, when the links 306 are received in the respective slots of the positioning element 364, the links 306 are prevented from moving in the direction of the arrow F which extends substantially substantially parallel to a longitudinal axis 366 of alignment housing 304. The element d The alignment 352 further includes an alignment surface 368 extending toward an alignment rib 370 adjacent to the leading edge 348 of each wall 340. The alignment surface 368 is flat and extends substantially parallel to the engagement surface 301 (shown in Figure 15) when the alignment housing 304 is mounted to the circuit board 303. In addition, the alignment surface 368 is in a spaced relation with the engagement surface 301, when the transverse channel assembly 300 is mounted to the circuit board 303, so that the links 306 can extend between the alignment surface 368 and the engagement surface 301. The rib of alignment 370 and the alignment surface 368 are laterally separated from the positioning element, so that the positioning element 364 is located between the alignment surface 368 and the opening extending between the internal side edges 346 of the side walls. 340. As will be explained later, the alignment surface 368 provides a recording surface which ensures that the ends of the contacts 306 are copied to each other. The preload of the contacts 306 against the alignment surface 368, as will be explained below, prevents the contacts 306 from moving in the direction of the arrow G, in which it extends perpendicular to the longitudinal axis 366. In an exemplary embodiment, the monolith features on the launder 308 extend outward from each of the side walls 340 adjacent the edges of the bottom 344 thereof. In the illustrated embodiment, features of board assembly 308 include holding holes 374 for receiving fasteners (not shown) therein. The fasteners serve to mount the alignment housing 304 to the circuit board 303. In In an alternative embodiment, mounting seats of the welding fastener may extend outwardly from the side walls 340 to locate and / or retain the welding fasteners therein, to mount the mounting housing 304 in position with respect to the circuit board 303. The mounting features on the board 308 can be precisely positioned with respect to the alignment surface 368 as described below to achieve the coplanarity of the contacts 306 with the alignment surface 368. In the For example, the alignment housing 304, including each of the aforementioned features, is integrally formed from an electrically insulating material (i.e., non-conductive material), such as plastic, as described in an exemplary embodiment. known process, such as a. injection molding process. However, it is recognized that the housing 304 can be formed alternally from separate parts and from other materials different from those known in the art. Figure 18 is a side elevation view of a first contact 380 which can be used in the upper row of the contact apertures 322 (shown in Figure 16) of the contact housing 302 (shown in Figures 15 and 16) . In an exemplary embodiment, the counted 380 includes a counted section 382, an aperture section 384, a forming section 386, and a welding section 388. The forming section 386 can be flexed and / or manipulated during the assembly of the transverse channel assembly to substantially orient the contact in relative position to the contact housing 302 and / or the housing of alignment 304 (shown in figures 15 and 17). The opening section 384 is dimensioned to produce an interference fit when inserted into an opening in the upper row of the contact apertures 322, and the contact section 382 and the forming section 386 are aligned with each other along the a common central line. A small radius is formed at one end 392 of the welding sections 388. The radius creates a rounded edge 392, which as will be appreciated below, mitigates the tolerances or misalignment of the contact 380 as the assembly is assembled. transverse channel 300. In an alternative embodiment, the radius may be omitted and the contact ends 380 may be straight. Although in Figure 18 a simple contact 380 is shown, it will be understood that the contact 380 is part of a group of counted including a number of counted corresponding to the number of counted openings in the counted rows 322 (shown in the figure). 17). The group of contacts can be manufactured from a single piece of metal, such as copper or copper alloy, and can also be covered or coated with tin, lead, gold, etc., as needed to obtain the characteristics and desired mechanical and mechanical properties of the conlaclo group. Figure 19 is a side elevational view of a second contact 400 which can be used in the lower row of contact openings of the counting housing 302 (shown in Figures 15 and 16). In an example embodiment, the contact 400 includes a contact section 402, an opening section 404, a forming section 406, and a welding section 408. The forming section 406 can be flexed and / or manipulated during assembly. of the cross channel assembly for substantially orienting the contact in a position relative to the counter housing 302 and / or alignment housing 304 (shown in Figures 15 and 17). The perforation section 404 is formed and sized to produce an interference fit when inserting into an aperture in the row of contact apertures, and the contact section 402 and the forming section 406 are aligned with one another along a length of common central line. In an alternative embodiment, the second contacts 400 can be compensated in a manner similar to that of the second links 170 shown in FIG. 5. Because the contact 400 is installed to the lower row of the contact openings, the contact 400 is relatively closer to the alignment rib 370 (shown in Figure 17) when the cross channel assembly 300 is assembled. Therefore, the second cone 400 has a length M more corolla than the first connector 380, which is installed to the upper row of contact apertures 322 in contact housing 302. A small radius is formed at one end 412 of welding sections 408 The radius creates a rounded end 412 which, as seen below, mitigates the tolerances or misalignment of the contact 400 as the transverse channel assembly 300 is assembled. In an alternative embodiment, the radius may be omitted and the Contact ends 400 can be straight. Although a simple contact is shown in Figure 18, it will be understood that the counted 400 is part of a group of counted including a corresponding number of contacts, to the contact apertures that exist in the contact rows. The contact group may be made of a single piece of metal, such as copper or a copper alloy, and may also be coated or coated with tin, lead, gold, etc., as necessary to obtain the characteristics and electrical properties and desired mechanics of the contact group. Figure 20 is a side elevational view of the contact housing 302 and the contacts 380 and 400 in a first manufacturing step, wherein the counted 380 and 400 are inserted in the upper row of the contact apertures 322 and the row bottom of the contact apertures (as shown in described and illustrated in Figure 20 through reference number 324). Specifically, the contacts 380 and 400 are inserted into the apertures 322 and 324 so that the forming sections 386 and 406 and the welding sections 388 and 408 are extruded from and externally located to the contact interface 316. of the cone housing 302. Furthermore, and in contrast to the method for forming the cross channel assembly 200 shown in FIGS. 8 to 14, the contacts 380 and 400 are completely insertioned from the flexion, thus eliminating the passage of assemble In the illus- trated embodiment, the accommodation of cones 302 is oriented with respect to the engaging surface 301 of the circuit board 303. Therefore, the longitudinal side walls 312 of the counter housing 302 define a surface of the bottom 420 located next to the circuit board and a top surface generally opposite 422. The links 380 and 400 are oriented within the contact housing 302, so that the rounded ends 392 and 412 curve upwards in the direction of the upper surface 422. In addition, the rounded ends 392 and 412 are oriented to engage the alignment housing 304 (shown in Figures 15 and 17) when the assembly of the transverse channel 300 is assembled. The alignment seats 330 extend outwardly from the side wall 314 and are positioned close to the counted interface 316 of the counted housing 302. In an exemplary embodiment, the alignment seats 330 are in a vertical stacking configuration above the circular of the circuit 303 and provide a keyed feature for coupling the alignment housing 304 (shown in FIG. Figures 15 and 17) to the housing of connectors 302. The latch 336 extends outwardly from the alignment seat 330 positioned proximate the surface of the bottom 420. In an exemplary embodiment, tooling may be employed, such as metal punches. formation for flexing the forming sections 386 and 406 and / or the welding sections 388 and 408 towards the bottom surface 420 of the contact housing 302. In an exemplary embodiment, and in contrast to the contact groups 150 and 170 in where the contacs flex at an angle of approximately 90 °, the contacts 380 and 400 flex at an angle of between about 15 ° and 45 °. . In one embodiment, the contacts flex at an angle of approximately 30 °. Therefore, the loops 380 and 400 can be assembled or formed more quickly compared to the contact groups 150 and 170. Although the embodiment described, therefore includes the bending of the counted 380 and 400 after they are installed in the counted housing 302, it is recognized that counted 380 and 400 can be flexed prior to installation to the contactor housing 302 in an embodiment alíernaliva. Figure 21 is a perspective view of the bottom of the transverse channel assembly 300 in a second fabrication step, where the alignment housing 304 is monial to the housing of connectors 302. During assembly, the mounting of the contact housing 356 is positioned relative to the alignment seats 330 and alignment seat 304 is mounted or installed in the contact housing 302. Specifically, the mounting of the contact housing 356 is aligned with the alignment seats 330, generally above the upper surface 422 of the counted housing 302 and moves in a generally downward direction, vertically toward the bottom surface 420 of the counted housing 302, or in the direction of the arrow H. At least one advantage of having an assembly of transverse channel of two pieces 300, is that the counted 380 and 400 can be installed and oriented with respect to the accommodation of conical 302 without inferring with the alignment housing 304 and / or the alignment rib 370. Specifically, only after the contacts 380 and 400 are placed, the alignment housing 304 is mounted to the housing of links 302. Once assembled, alignment lugs 330 are placed inside and fit with the internal surface of mounting cavities 358. In an example embodiment, the alignment seats 330 have an interference fit with the mounting cavities 358, so that the alignment housing 304 is securely mounted to the contact housing 302. In addition, the notches 362 within the retaining clips 360 are positioned to fitting latches 336 extending from the alignment seats 330. Accordingly, the retaining clips 360 can secure the alignment housing 304 to the contact housing 302. During assembly, the contacts 380 and 400 are oriented in a generally vertical fashion below the alignment rib 370 and the positioning element 364. Therefore, when the alignment housing 304 is mounted in the contact housing 302, the alignment rib 370 engages with the counted 380 and 400. In addition, the Welding sections 388 and 408 fit through the slots in the positioning element 364, and we will exempt them rounded 392 and 412 of the sections Respective weldings 388 and 408 are aligned with each other and in a bearing contact with the alignment rib 370. As shown in Figure 21, the alignment surface 368 is rounded and coroneted and formed to lightly contact with the rounded edges 392 and 412 of the connectors 380 and 400. When installed, the welding sections 388 and 408 flex from the position shown in FIGS. 20 and 21 in a generally downward direction vertically toward the bottom surface of the contact housing 302, thereby creating an internal tilt force on the contacts 380 and 400, which preload the welding sections 388 and 408 against the alignment surface 368 of the new alignment rib 370. Figure 22 is a perspective view of the bottom of the assembly of the transverse channel 300 in a final manufacturing step, wherein the contacts 380 and 400 are substantially aligned along the alignment rib 370. In the embodiment illustrated, the housing alignment 304 sits completely against and is secured to the contact housing 302. When assembled, the bottom edges 344 of the side walls 340 and the bottom surface of the moniage features in the 308 spoke are coplanar with the exits of contact 392 and 412 of the counted 380 and 400. The transverse channel assembly 300 is therefore well suited for surface mounting. to the latching surface 301 of the circuit board 303 (shown in FIG. 15). When assembled, welding sections 388 and 408 preload and support the alignment surface 368 of the alignment rib 370 at a corner of the transverse channel assembly 300. Said biasing or preloading of the welding sections 388 and 408 prevent subsurface movement of the veri- welding 388 and 408 in the direction of the arrow I, since the assembly of the transverse channel 300 is manipulated by the anvil of the moniary on the surface and during the installation installation on the surface. Manufacturing tolerances, in the manufacture of those counted 380 and 400 are mitigated and the welding sections 388 and 408 are substantially aligned and coplanar for mounting to the circuit board 303. Subsequently, relatively thin and consistent solder paste films can be used to reliably weld the cross channel assembly 300 to the circuit board 303. In an exemplary embodiment, the annular alignment surface 368 of the alignment rib 370 and the rounded ends 392 and 412 of the welding sections 388 and 408, allow for some misalignment of the sections of welding 388 and 408 as the contacts 380 and 400 are installed. The alignment surfaces rounded 368 at the ends 392 and 412 of the connectors 380 and 400 allow the displacement of the contact points between the surfaces as the contacts 380 and 400 move to the final position. Since the welding sections 388 and 408 are pre-loaded against the alignment rib 370, the relative misalignment of the welding sections 388 and 408 is substantially, if not completely eliminated, and the rounded edges 392 and 412 of the contacts 380 and 400 are substantially aligned to produce counted points tangential coplanar to the rounded edges 392 and 412 for mounting to circuit board 303. For all of the above reasons, a safe and reliable 300 transverse channel assembly is provided for surface mount applications, which has the ability to withstand forces higher insertion and extraction when the transverse channel assembly 300 engages and disengages from the coupling connector. The transverse channel assembly 300 includes a coniferous housing 302 and an alignment housing 304 mounted to the contact housing. During assembly, the contacts 380 and 400 are loaded into the contact housing 302 and aligned for engagement with the aligning housing 304. Optionally, a conjoint housing 302 can be used and re-adjusted for this particular application. As a result, manufacturing and development costs can be reduced. In addition, as the alignment housing 304 is set in the contact housing 302, an alignment rib 370 engages the rounded edges 392 and 412 of the contacts 380 and 400. When fully assembled, the alignment rib 370 is aligned substantially with the contacts 380 and 400 to produce coplanar contact points for the engagement of the surface with a circuit board 303. As a result, a reliable and reliable 300 cross-sectional channel assembly is provided which ensures the coplanarity of connectors 380 and 400 for surface mounting to circuit board 303. Although the present invention has been described in terms of several specific embodiments, those skilled in the art will recognize that the present invention can be practiced with modifications within the spirit and scope of the appended claims.

Claims

CLAIMS 1. A transverse channel assembly (300) comprising an insulating contact housing (302) having a plurality of walls (312, 314, 316) defining an interior cavity (318) and a plurality of contacts (306) within the cavity and extending from one of the walls to the former part of the socket of the joints, wherein the cross-channel assembly is characterized by; an insulating alignment housing (304) comprising at least one alignment rib (352) extending on an outer surface thereof, the alignment housing being separately provided and mounted independently of the counting housing; and wherein the counters (306) flex against the alignment housing (304) and rest on the alignment rib (370), ensuring in this way the coplanarity of the contacts for surface mounting to a circuit board.
2. A transverse channel assembly as described in claim 1, characterized in that the alignment housing (304) comprises a plurality of walls (340, 350) defining an alignment cavity (354), and the housing of contacts. it comprises a counted interface (316), wherein the contacs (306) extend through the contact information in a plurality of rows in the alignment cavity.
3. A transverse channel assembly as described in claim 1, characterized in that the alignment housing (304) is releasably mounted to the wall through which the plurality of contacts extend.
4. A transverse channel assembly as described in claim 1, characterized in that the contacts (304) are pre-loaded against the alignment rib (370).
A transverse channel assembly as described in claim 1, characterized in that the alignment rib (370) is positioned at a substantially uniform distance from an engaging surface (301) of a circuit board (303) so that a gap is defined between an alignment surface (368) of the alignment rib (370) and the engagement surface (301), the contacts (306) resting against the alignment surface (368) and substantially filling the aperture.
A cross-channel assembly as described in claim 1, characterized in that the alignment rib (370) engages with the counters (306) as the alignment housing (304) is mounted to the counting housing (302) , preloading in this way those counted against the alignment rib.
7. A transverse channel assembly as described in claim 1, characterized in that the alignment housing (304) further comprises a mounting feature on the blade (308) adhered to the exile surface thereof, the moniage characteristically comprising the A surface of lace on the circular path is coplanar with the conlactos when the conlactos rest against the alignment rib. A cross channel assembly as described in claim 1, characterized in that the alignment housing (304) further comprises a positioning element (364) comprising a plurality of grooves, wherein each plurality of conlaclos is engaged with a plurality of corresponding grooves.